Metal oxide-stabilized zirconium oxide ceramic materials

Abstract

The present disclosure relates generally to ceramic materials suitable for use as catalyst support materials, catalysts using such materials and methods for using them, such as methods for converting sugars, sugar alcohols, glycerol, and bio-renewable organic acids to commercially-valuable chemicals and intermediates. One aspect of the invention is a ceramic material including zirconium oxide and one or more metal oxides selected from nickel oxide, copper oxide, cobalt oxide, iron oxide and zinc oxide, the ceramic material being at least about 50 wt. % zirconium oxide. In certain embodiments, the ceramic material is substantially free of any binder or additional stabilizing agent.

We claim: 
     
         1 . A ceramic material comprising zirconium oxide and metal oxide, wherein
 the zirconium oxide is present in an amount within the range of about 50 wt. % to about 99 wt. % of the material;   the metal oxide is one or more of nickel oxide, copper oxide, cobalt oxide, iron oxide and zinc oxide; and   the metal oxide is present in an amount within the range of about 1 wt. % to about 50 wt. % of the material, calculated on metallic basis.   
     
     
         2 . The ceramic material of  claim 1 , wherein
 the zirconium oxide is present in an amount within the range of about 75 to about 99 wt. % of the material;   the metal oxide is present in an amount within the range of about 1 wt. % to about 25 wt. % of the material, calculated on metallic basis; and   wherein the ceramic material optionally includes one or more additional metal oxides present in an amount up to about 20 wt. % of the material, calculated on metallic basis.   
     
     
         3 . The ceramic material of  claim 1 , substantially free of chromium. 
     
     
         4 . The ceramic material of  claim 1 , substantially free of manganese. 
     
     
         5 . The ceramic material of  claim 1 , substantially free of silicon oxide, aluminum compounds, silica-alumina compounds, graphite and carbon black. 
     
     
         6 . The ceramic material of  claim 1 , wherein the zirconium oxide is predominantly in a tetragonal phase, an amorphous phase or both. 
     
     
         7 . The ceramic material of  claim 1 , wherein at least about 80 wt. % of the ceramic material is the zirconium oxide and the metal oxide. 
     
     
         8 . The ceramic material of  claim 1 , wherein the catalyst support material has a pore volume within the range of about 0.1 cm 3 /g to about 1.0 cm 3 /g; a surface area within the range of about 10 m 2 /g to about 400 m 2 /g; and a crush strength within the range of about 1.0 lb/mm to about 10 lb/mm. 
     
     
         9 . The ceramic material of  claim 8 , provided as an extrudate. 
     
     
         10 . The ceramic material of  claim 1 , wherein the metal oxide is iron, and the iron is present in about 5 wt. % to about 30 wt. % of the material, as calculated on metallic basis. 
     
     
         11 . The ceramic material of  claim 1 , wherein the metal oxide is cobalt, and the cobalt is present in about 5 wt. % to about 25 wt. % of the material, as calculated on metallic basis. 
     
     
         12 . The ceramic material of  claim 1 , wherein the metal oxide is nickel and the nickel is present in about 5 wt. % to about 40 wt. % of the material, as calculated on metallic basis. 
     
     
         13 . The ceramic material of  claim 1 , wherein the metal oxide is copper, and the copper is present in about 5 wt. % to about 35 wt. % of the material, as calculated on metallic basis. 
     
     
         14 . The ceramic material of  claim 1 , wherein the metal oxide is zinc, and the zinc is present in about 5 wt. % to about 25 wt. % of the material , as calculated on metallic basis. 
     
     
         15 . The ceramic material of  claim 1 , further comprising one or more additional metal oxides selected from oxides of yttrium, lanthanum, cerium, niobium, tungsten, molybdenum, titanium, calcium, magnesium, boron, tin and anitmony. 
     
     
         16 . A method for making the ceramic material of  claim 1 , comprising extruding a zirconium oxide-metal oxide precursor material in the absence of any binder, extruding aid or additional stabilizing agent. 
     
     
         17 . A catalyst comprising the ceramic material of  claim 1 , and a catalytically active material disposed on the ceramic material. 
     
     
         18 . The catalyst of  claim 17 , wherein the catalytically active material is a catalytic metal selected from Ni, Cu, Co, Fe, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, Au, Sb, La, Bi or any combination thereof. 
     
     
         19 . A method for the reduction of a sugar, sugar alcohol or glycerol, the method comprising contacting the sugar, sugar alcohol or glycerol with the catalyst of  claim 17  and a hydrogen source. 
     
     
         20 . The method of  claim 19 , wherein the reduction is conducted at a temperature within the range of 180° C. to 600° C., and a pressure within the range of about 1 bar to about 150 bar. 
     
     
         21 . The method of  claim 19 , wherein the reduction is conducted at a pH in the range of about 2 to about 12.